FREE Lean Six Sigma Green Belt DMAIC: Improve and Control Questions and Answers

Question 1

A project team has successfully identified several potential solutions to reduce shipping errors.
To objectively decide which solution to implement, they need to evaluate each option against criteria such as cost, implementation difficulty, and potential impact.
Which tool is most appropriate for this task?

Accepted Answer

Solution Selection Matrix

Answer

Fishbone Diagram

Answer

Control Chart

Answer

5 Whys

Question 2

Which of the following describes the primary purpose of conducting a pilot study during the Improve phase of a DMAIC project?

Accepted Answer

To test a proposed solution on a small scale to manage risk before a full-scale rollout

Answer

To identify the root causes of the problem being addressed

Answer

To validate the financial savings of the project for the final report

Answer

To create the final control plan and hand it off to the process owner

Question 3

A manufacturing team wants to prevent operators from installing a part backward. They redesign the part with an asymmetric tab that only allows it to be inserted in the correct orientation. This is an example of which lean technique?

Accepted Answer

Poka-Yoke

Answer

Kaizen

Answer

Kanban

Answer

5S

Question 4

After implementing an improvement to reduce the variability in the fill weight of a product, a team needs to monitor the process to ensure the gains are sustained. They will take samples of 5 boxes every hour and record their weights. Which SPC tool is MOST appropriate for monitoring the process average and variation over time?

Accepted Answer

X-bar and R Chart

Answer

Pareto Chart

Answer

Histogram

Answer

p-Chart

Question 5

What is the primary function of a Control Plan in the final phase of a DMAIC project?

Accepted Answer

To provide a detailed summary of actions for maintaining the process improvements

Answer

To document the brainstorming sessions from the Improve phase

Answer

To calculate the final Return on Investment (ROI) for the project sponsor

Answer

To perform a final root cause analysis on any remaining issues

Question 6

A project team is finalizing a Control Plan for an improved invoicing process. Which of the following elements is LEAST likely to be included in this document?

Accepted Answer

A detailed Voice of the Customer (VOC) analysis from the Define phase

Answer

The key metrics to be monitored (e.g., 'invoice accuracy rate')

Answer

The frequency of data collection (e.g., 'daily audit of 10 invoices')

Answer

A reaction plan specifying actions if accuracy drops below 99%